Work homemade machine

Nowadays, without exception, all building materials are constantly becoming more expensive, and corrugated board, which is very widely used in construction, is no exception. A material is produced from a sheet of metal, which is given a certain shape.

The main function of such a machine is cutting and rolling the workpiece, as a result of which it takes the form of a finished profiled sheet. In our time, a similar manual machine for the manufacture of corrugated board can even be made with your own hands, knowing how to work with metal blanks and, preferably, having engineering skills.

Automatic and manual machines for the production of profiled sheets

The main difference between a profiled sheet and other similar metal sheets is that the corrugation has trapezoidal shape. At first glance, it may seem that it is impossible to make a machine for the production of such material on your own, but this is not so.

The production lines of such material are a whole complex of mechanisms, each of which performs its own functions.

So, even the simplest automatic line for the production of profiled sheets consists of:

unwinder of rolls of metal sheets;
rolling mill, on which the formation of the material is actually carried out;
scissors that look like a guillotine;
receiving device.

Production Line for the production of profiled sheets

It is clear that it is unrealistic to make such an automatic line on your own. But here it is quite possible to make a manual machine that can bend the blanks to the desired angle so that a sheet of corrugated board is obtained.

It should be borne in mind that a home manual machine will not be able to produce too thick profiled sheets - the maximum thickness of the workpiece is about 5 mm.

Preparation of supports and a table for feeding workpieces

Self-manufacturing of a rolling machine begins with assembling a frame to accommodate all the components of the equipment. In this case, it is enough to install reliable supports, fixing them on the base: preferably on a concrete floor.

Next, a table is assembled, on the surface of which the workpiece will be fed into the machine. Its length should be several times the length finished product, since the surface will require the presence free space to receive the finished product. The optimal material for the table surface is aluminum sheet.

There should be a special bar on the table, which, with the help of bolts, can fix the workpiece on the table. In the same way, a manual lever is fixed, which feeds sheets of material across the table into the machine for corrugated board, setting the required feed angle.

Installation of rolls and first start-up

The next component - rolling shafts - is very difficult to assemble with your own hands, so it is best to purchase them ready-made. Finding such devices on the market today is not difficult.

With brackets from metal corners shafts are fixed on the frame of the machine near the hand lever.

Having tightened all the bolts not at full strength, the almost completely made manual machine for the production of corrugated board is ready for the first run-in of the material. If the manufactured corrugated board has the desired shape, the parts can be fixed in place by firmly tightening all the bolts. Otherwise, adjustment of certain parts is carried out, and the procedure is repeated.

Features of working with a homemade manual machine

Even if you are an experienced craftsman, you should be very careful when working on a machine made with your own hands, since any malfunction in any component of the mechanism can lead to injury during its use.

At the same time, one should not forget about safety precautions, working with extreme caution, especially if a guillotine is used to cut metal.

Thus, the self-assembled machine for corrugated board is ready. Its principle of operation is very simple:

the blank sheet is placed on the table;
with the help of a special bar, the workpiece is fixed on the table;
using a manual lever, the optimal angle of material supply to the rolling shafts is set;
at the exit, the finished sheet should move freely around the table.

In order not to get any industrial injuries, when working with such a machine, it is necessary to constantly adhere to safety regulations.

The machine that produces the corrugated board is a very dangerous piece of equipment because it has many cutting and piercing components that can be dangerous to the operator. Therefore, work on the machine is only allowed in protective clothing and goggles.

Before each work with such a hand-held device, the performance of all its components should be carefully checked. On manual machines, it is highly recommended not to bend very thick metal sheets.

Thus, having the skills to work with metal materials, even with your own hands you can make a mechanism for rolling a profiled sheet, which will provide enough high quality received products. The main thing is not to make any mistakes when assembling it, and also remember the rules safe use sheet metal equipment.

Do-it-yourself drawings for making a machine

Overview of factory models

Profiled sheet production - what equipment is used?

The production of a reliable, small in weight and inexpensive profiled sheet used in the construction industry of our days is carried out on special manual and automatic equipment.

What you need to know about the production of profiled sheets?
What aggregates are used for the production of profiled sheets?
Standard line for the production of corrugated board - what does it include?
What factors affect the quality of a profiled sheet?

1 What you need to know about the production of profiled sheets?

Decking - universal modern material for the construction of low-rise buildings, wall cladding, roofing and other construction tasks, it is made from cold-rolled galvanized steel sheet. To give such rolled products the required shape, only two methods are used - hot and cold rolled. Both of these operations involve the passage of flat sheets of steel through special shafts.

Hot-rolled technology, due to its features, is available exclusively at large metallurgical plants.

But cold rolling of steel billets in order to obtain profiled sheets from them can be performed in semi-professional and even amateur conditions. The main thing here is to choose the right equipment and learn how to use it correctly.

The technology for the production of wall and roof profiled sheets by cold rolling consists of two procedures following one after another. First, the workpiece is passed through the rollers, and then the resulting corrugated board is cut according to the given geometric sections. The shape of the rollers determines, as you yourself understand, the shape of the finished product.

The simplest manual machine for the manufacture of profiled sheets is able to "give" us products of only one shape. In those cases when an automated line for the production of profiled sheets is used, it, as a rule, makes it possible to obtain products of different assortments and shapes. Such diversity is achieved due to the fact that automated equipment makes it possible to change the settings of the rollers.

2 What machines are used for the production of profiled sheets?

Production is possible on installations of three main types:

manual machine;
mobile (mobile) equipment with partial automation of work operations;
fully automatic lines.

Any person can use an elementary machine for the production of profiled sheets, but on condition that he is ready to make quite serious physical efforts to process steel sheets. On the manual settings Usually billets of small thickness are rolled. The quality of the resulting products is at a low level. In most cases, such a machine is used for the production of profiled sheets for fences and fences.

Manual equipment does not have to be purchased ready-made. There are a huge number on the Internet detailed drawings and schemes, guided by which you can independently make the simplest bending machine. We note again - it makes no sense to use it for the production of really high-quality profiled sheets. You simply won't be able to do anything.

Partially automated equipment for the production of corrugated board allows you to produce many times more professional products. Such units are equipped with an electric drive, they have a relatively small weight, which allows them to be carried and used directly at those facilities where low-rise construction is carried out, the construction of storage facilities for agricultural products and warehouses, hangars, fences, and so on.

Semi automatic equipment in terms of the efficiency of its work and the quality of the profiled products produced, it is in no way inferior to fully automated lines. At the same time, it is mobile, which in some cases is of great importance.

A stationary automatic line is a whole complex of units. Depending on the specific configuration, it may include the following settings:

directly rolling mill with rollers of several sizes;
device for cutting profiled sheets;
equipment for applying a polymer coating to finished products.

Also, as part of automated lines, there is sometimes a unit for loading operations. It is clear that such complexes have a high cost. But their performance is many times greater than the capabilities of manual and semi-automatic machines. It makes sense to invest in automatic equipment when you plan to work long and fruitfully in the field of manufacturing and selling profiled sheets with all kinds of geometric parameters.

3 Standard line for the production of corrugated board - what does it include?

Experts say that the following mechanisms and devices should be present in the minimum configuration of automated equipment for the production of high-quality profiled sheets:

The corrugated board production line is controlled by special system. It can be both relatively simple and really complex. A simple control system does not provide a high level of automation of the production process, but people with low qualifications can work with it. But a complex equipment control complex increases the efficiency of the line. True, not everyone will be able to deal with such a system, for its use it is necessary to attract specialists with a large amount of technical knowledge.

4 What factors affect the quality of the profiled sheet?

The workpiece in the production of profiled sheet products on automatic lines directly depends on the number of rollers for rolling. They are placed in pairs one above the other. There is a small gap between the individual pairs of rollers. The steel sheet from which the corrugated board is made is slightly less than the specified gap in thickness (and sometimes these figures are the same).

The initial workpiece is passed through the rolling shafts, and this procedure is carried out several times in a row, since it is usually impossible to achieve the required sheet shape in one pass. In one run, the workpiece is bent between the rolls by a certain amount. At the same time, minimal pressure is exerted on it, which ensures a perfect result of the final deformation.

It is important not to overdo it with the number of pairs of rolls. If the workpiece is passed through too many of them, there is a possibility that the zinc coating of the steel sheet will be destroyed. In addition, the quality of profiled sheets is influenced by the quality of steel alloys from which rolling shafts are made and the level of cleanliness of their processing.

Experts advise purchasing equipment from foreign manufacturers (for example, Finnish) or domestic production lines, and never pay attention to units for the production of profiled sheets from Chinese companies. And the last. If possible, it is better to buy new rather than used profiled sheet production lines, since the technical capabilities of the latter are usually at a very low level due to their wear and tear.

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Profiled sheet production: serious equipment and manual machines

Profiled sheeting has been actively used in the field of construction and in many other areas for several decades now. This reliable material, the manufacture of which requires a special machine for the production of corrugated board, is used as the main element of building envelopes, they cover the roofs of building structures, line walls, and also solve a whole list of other tasks related to both capital and private construction.

Decking is made by cold rolling

The production of profiled sheets can be carried out both on mechanized and on manual equipment, which, if desired, can be made with your own hands. Knowing all the nuances of such production, you can organize a profitable business for the manufacture of profiled sheets in demand on the market or with minimal cost produce such material for their own needs.

Properties of corrugated board

Decking, which is represented by several main varieties on the modern market, can be made of various materials. However, the main raw material for the production of profiled sheets is cold-rolled sheet steel, on the surface of which a thin layer of zinc is applied. To give the steel sheet the required configuration, a rolling method is used, which can be performed in a hot or cold state. The production of corrugated board, in which the steel sheet is preliminarily subjected to significant heating, is carried out only by large metallurgical plants. At home, or on the scale of a small manufacturing enterprise, the profiled sheet is produced by cold rolling.

The main types of profiled sheet

Depending on the conditions of further use and the loads that the profiled sheet will experience, steel of various thicknesses can be used for its manufacture. Instead of a zinc coating, a layer of paint or other material can be applied to the surface of the profiled sheet, which is able to provide reliable protection sheet metal from negative impact external environment. Given the fact that corrugated board structures are mainly used outdoors, the presence of a coating that protects them from intensive wear under the influence of corrosion makes it possible to endow such material with the required durability.

Conditions in which the equipment for the production of corrugated board is operated. also affect the quality of the finished product. So, it is desirable to install both a manual machine used for the manufacture of corrugated board and an automated line for the production of such material in a dry and heated room, in which there are no sharp drops temperature regime. The conditions in which the raw materials for the manufacture of profiled sheets are stored - sheet steel rolls - also play a role. The room in which such storage is carried out must also be dry and heated.

Types of equipment for the production of corrugated board

Any equipment for the production of corrugated board works according to a standard scheme. A flat steel sheet to give it the required configuration is driven through a system of rolls, which are equipped with a machine used for the production of corrugated board. As a result of such a technological operation, a flat steel sheet is deformed, acquiring the required geometric shape.

The dimensions and shape of the rolls depend on the configuration of the profiled sheet produced on the machine

As the main raw material from which the profiled sheet is made, as mentioned above, sheet steel is used, supplied from manufacturing plants in rolls. If the steel sheet rolled into such a roll has a small thickness, then unfolding it will not be a big problem: this can even be done manually. The situation is quite different if it is necessary to use sheet steel of considerable thickness for the profiled sheet. In this case, the machine used for the production of profiled sheets needs to be equipped with an additional device that will be responsible for bending sheet metal of considerable thickness.

The machine for corrugated board, depending on the required performance, can be equipped with a manual or mechanized drive. Of course, a manual machine for the production of corrugated board is distinguished by a simpler design. Meanwhile, deciding to use such equipment, it should be borne in mind that working on a manual machine for the production of profiled sheets requires considerable physical effort, so it is problematic to use such a device for the manufacture of profiled sheets of considerable thickness.

The LSP-2000 manual profile bender is designed for the manufacture of profiled sheet or metal box with a thickness of up to 0.55 mm

Meanwhile, the manufacture at home of a machine equipped with a mechanized drive for the production of corrugated board is also associated with certain difficulties. The fact is that in such equipment for corrugated board there should be a device that provides cutting of profiled sheets into products of a certain length. To perform this technological operation, ordinary guillotine shears are not suitable, since this requires devices whose working bodies in their shape fully correspond to the configuration of a profiled steel sheet.

Profile forming on a specialized line takes place at a rolling mill

There are two technologies that can be used to manufacture corrugated board on specialized equipment. The first of them is called simultaneous profiling and involves the deformation of both sides of the steel sheet used for the manufacture of the profiled sheet. Corrugated sheeting machines, working on the principle of sequential profiling, separately deform each side of the steel sheet.

The most effective in the manufacture of profiled sheets is a specialized line for the production of corrugated board, the structure of which already contains all the necessary equipment.

Structure of production lines

To ensure the high quality of the manufactured products, the corrugated board production lines must be equipped with the following mechanisms and devices.

In such a line, a mechanism is required that ensures the fixation of rolls with sheet steel, as well as their unwinding. The production of steel profiled sheets on an industrial scale involves the use of sheet metal rolls as raw materials, the weight of which can reach up to ten tons. Manipulating such rolls without the use of special devices is almost impossible.
A special device allows you to automatically adjust the degree of sagging of the workpiece between the unwinding mechanism and the receiving part of the machine. The corrugated board production line usually processes sheet metal at a high speed, which simply does not allow manual adjustment of the sag of the workpieces.
To ensure high productivity and the required quality of manufactured products, professional equipment for the production of metal profiles is equipped with several groups of work rolls. Such groups of rolls, which are called stands, perform various functions while being part of an automated line for the production of profiled sheet. As a rule, these stands, consisting of a different number of work rolls, are used to load sheet metal into the processing zone of the equipment, to perform work operations and unload the finished product from the machine.
The production line has a drive mechanism, which must have sufficient power to ensure high productivity of technological operations associated with the production of profiled sheet by rolling.
The cutting device, which is equipped with professional equipment for the production of profiled sheets, must provide high-quality cutting of the finished product, without the formation of burrs and bends at its edges. The presence of such defects significantly reduces the cost of the finished product.
The machine for the manufacture of corrugated board in industrial volumes must also be equipped with a compartment in which finished products are stored.

The structure of the automatic sheet production line

A production line intended for the manufacture of profiled sheets can be controlled by an automated system or a simpler device that is not able to provide the proper level of process automation. Meanwhile, even operators with a low skill level can use a corrugated board machine controlled by a simpler device.

How to make a machine for the production of profiled sheets

A machine for making a sheet, the profile of which has a trapezoidal configuration, can also be made by hand. However, it should be borne in mind that such equipment will have limited technical capabilities and it will be possible to use it for processing blanks from sheet metal of small thickness. Such a home-made machine can be used not only for the production of profiled sheets, but also for the manufacture of elements of roof structures - skates, cornice strips, etc.

A drawing of a homemade sheet bender, which can also be used to make a profiled sheet

The basis of such a machine, the details of which can be found in the video, is a frame mounted on a concrete base and fixed on it with anchor bolts. On such a frame, a desktop is mounted, the length of which must exceed the length of the workpieces being processed. The desktop of a home-made machine designed for the production of corrugated board is used both for feeding the workpiece into the processing zone and for extracting the finished product.

To securely fix the sheet metal roll on the machine frame, a special bar is used, which is fixed with a bolted connection. The mechanical impact on the processed sheet metal, from which the profiled sheet is formed, is carried out by means of a manual lever mounted on the equipment frame. With the help of such a lever, the design of which can be additionally equipped with a clamping spring, not only the feeding of steel sheets into the processing zone is carried out, but also the angle of their feeding is adjusted.

When making a manual machine for corrugated board on your own, it should be borne in mind that it will not be possible to completely make such equipment with your own hands: some elements of its design will have to be ordered from metalworking specialists. Such elements, in particular, are rolling shafts, with the help of which the required profile of the workpiece is formed.

For the manufacture of this mobile profile bender, you will need bearings, a corner and pipes

Carriage - the main unit of a homemade machine

The rolling shafts of the machine designed for the production of corrugated board are fixed on the frame with brackets and connected to a lever that controls their operation. The metal blank, from which the profiled sheet will be formed, is fixed on the surface of the machine's desktop with special paws or strips.

Before you securely fix all bolted connections in the design of a home-made machine designed for the production of profiled sheets, test bending should be performed on such equipment. Its results will show the need for adjustment or alteration of mechanisms.

Price: 370,000 rubles.

Rolling mill for corrugated board. The equipment makes it possible to produce a popular building material on the market - profiled sheet C8. The moderate cost of this machine at 370,000 rubles makes it the most affordable among other offers of similar equipment. Reliable and easy to use. The quality of the produced profiled sheet corresponds to GOST. Roller knife on a frame for cutting a metal sheet as a gift.

Here are brief technical characteristics of the rolling mill:

Produced profile: C 8
sheet thickness: from 0.4 mm to 0.7 mm
raw material type: galvanized or sheet with polymer coated(painted)
maximum productivity: up to 8 m.p./min.
number of profiling stands: 7
power supply, depending on the modification of the equipment: 220V or 380V
power: 2.2 kW
dimensions: 3.75x1.60x1.1 m
weight: 870 kg
the machine for corrugated board is equipped with a reverse and an emergency stop button

The line for the production of corrugated board, which we sell in Moscow, has universal technical characteristics - the equipment can be placed in almost any room, including a small area. Profiled sheets are produced by cold rolling, when the metal passes through 7 profiling stands. During the production process, the desired shape is acquired and the output is C8 corrugated board with the correct sheet geometry.

This equipment for the production of corrugated board in Moscow has the most elaborate design, which provides significant advantages. For example, in a rolling mill, an inlet unit is installed to receive a sheet. Durability is provided by a strong steel frame, the force on the shafts is transmitted by chains. The resource of working shafts and frames is increased. Our machine for the manufacture of corrugated board in Moscow turns on, off, and also spins in reverse side when given the appropriate commands from the control unit.

The corrugated board line, which we sell in Moscow, allows you to quickly master all aspects of the production process and get to work. The operator needs to submit a rental sheet to start profiling. After that, it remains only to accept the finished product at the exit. Therefore, we can say that our machine for the production of corrugated board in Moscow is quite easy to learn. Any worker who has passed a simple training within a few hours can become a line operator.

The machine for the manufacture of corrugated board in Moscow can work with a metal sheet with a thickness of 0.4 to 0.7 mm. The raw material is galvanized or painted (with a polymer coating) sheet. It can be easily purchased in various regions. It is sold at metal-roll dealers and at metal bases, both in rolls and cut.

It is important to add that with the help of our rolling mill it is possible to form a complete line for the production of C8 corrugated board. At the same time, the cost of such equipment will be significantly lower than analogues. And most importantly, it will be possible to work with rolled metal.

Such a line of corrugated board can be formed if the rolling mill purchased from our company is supplemented with a rolled metal decoiler and a roller knife for cutting metal sheets. In this case, the production process is built as follows: first, the rolled sheet is fed from the unwinder to the cutting table, where it is cut by the operator into right size by lenght. Then, the sheet already prepared for profiling is fed into the rolling mill, passes through the profiling stands, acquires the desired shape, and the output is the finished product - C8 corrugated board.

It is important to note that according to the campaign held at our enterprise, the buyer will receive a roller knife on a frame for cutting a metal sheet when purchasing a rolling mill and an unwinder for free.

Uncoilers are available in two versions - manual for 75,000 rubles and electromechanical for 145,000 rubles. The cost of this equipment is moderate, the load capacity is 7 tons. They perfectly complement the machine for the production of corrugated board and allow you to unwind metal coils with a width of up to 1250 mm and a thickness of up to 0.7 mm. In the case of manual modification, the operator unwinds the coiled steel by turning the handwheel. The electromechanical unwinder is equipped with an electric drive and a frequency converter, which makes it easy to control different modes of sheet feeding for cutting and profiling.

Thus, our equipment for the production of corrugated board has an important advantage - low cost. For example, if we add together the price of a rolling mill and a manual roll decoiler, we get a complete line for rolling C8 corrugated board for only 445,000 rubles.

In addition, we will note one more promotion for all those who have bought our equipment for corrugated board . They receive a 50% discount on the purchase of a semi-automatic machine for making chain-link mesh. In other words, our customers have the opportunity to purchase a ready-made chain-link machine for only 20,000 rubles. This is an efficient equipment, the performance and technical characteristics of which will allow you to set up the production of mesh in a wide range - with different size cells and wire thickness. In addition to C8 corrugated board, the chain-link can be an excellent addition to the line of your products that you can offer on the market.

In general, this line of activity - the production and sale of C8 corrugated board can be called quite profitable. It is not difficult to ensure its stable sales. It is well known in the market - consumers are well aware of the benefits of this building material. Reliability and durability make it a popular commodity, as well as simply acceptable appearance, which it gives to buildings and territories where it was used in construction. The profiled sheet is widely used both in private housing construction and in the construction of industrial and commercial facilities. The specificity of C8 corrugated board is its use mainly as a building material for mounting walls and fences. When covering the roof, it is used less frequently, although if desired and an increase in the angle of inclination of the roof, C8 corrugated board can also be laid.

Using our corrugated sheeting equipment, you can make the entire process of working and organizing a business for the production of corrugated sheets as convenient and simple as possible. You need to complete just a few steps - buy a machine for corrugated board, install it and start working. One year warranty. Service maintenance. We help all clients to organize delivery to any point in Russia and the CIS countries. For detailed advice from our experts on technical specifications, purchase and delivery of a line for the production of corrugated board, contact us by phone or all the indicated feedback forms.

Machine for the production of corrugated board

Metal profiled sheet, without exaggeration, can be called the most versatile building material. Due to the high demand, its production, and, as a result, the manufacture and sale of machines for the production of corrugated board, is a very profitable business.

An example of a corrugated board machine with partial automation

There are two main types of equipment for the production of corrugated board - these are manual machines used to produce small volumes of corrugated board, and automatic and semi-automatic rolling mills, which produce metal profiled sheet on an industrial scale.

Manual machine for the production of corrugated board

The manual corrugated sheet machine can roll metal sheets up to 2.5 m long and is an alternative to high-capacity industrial rolling mills in cases where small batches of corrugated sheets need to be produced.

For example, such a machine is almost indispensable in cases where it is necessary to mount roofing at remote sites. In these cases, the delivery of a metal profiled sheet to the site can often be much more expensive than the cost of its manufacture.

The manual profiled sheet machine is easy to maintain and is driven by human muscle power. Moreover, due to the leverage system, a lot of effort is not required.

Manual machine for the manufacture of corrugated board

A manual corrugated sheeting machine, which costs about $2,000, will pay for itself within two to three weeks, even if it only produces 50-100 corrugated sheets per day. Provided that the productivity of such machines can reach 300 m² of profiled sheet per day, and even more. As payback example such a solution, we will calculate the cost of a profiled sheet produced on such a machine.

The average price of rolled thin-sheet galvanized steel is about 1300-1500 US dollars per ton. From this amount of metal, it is possible, using a manual corrugated sheet machine, to produce approximately 250 m² of corrugated sheet in just one day. Knowing that the price of a galvanized steel sheet is about 8 US dollars per square meter, we can calculate that the cost of 250 m² will be 2,000 US dollars. Thus, in addition to the cost of the metal, buying such a quantity of finished corrugated board, you will pay approximately 600 US dollars for its manufacture.

Based on the given data and taking into account how much a corrugated sheeting machine costs, it is easy to calculate the payback period for this investment. As a rule, it is only a few weeks.

The advantages and disadvantages of manual machines for corrugated board include the following:

small production area. necessary to accommodate such equipment;
easy reconfiguration the number of waves or profile trapeziums;
high performance(two workers in one shift can produce up to 300 m² of corrugated board);
does not require electricity ;
reliability and simplicity in maintenance and operation;

Many modifications of such equipment, such as, for example, a machine for the manufacture of profiled sheet SPR-2.1, manufactured in Ukraine, can produce products not only from galvanized metal, but also from thin sheet steel with a polymeric protective and decorative coating.

Profiled sheeting machine with cutting module

Many machine-building enterprises in Europe and the CIS countries manufacture machines for the production of profiled sheets, so it will not be difficult to buy a machine for profiled sheeting.

The machine for the production of corrugated sheet works as follows:

with the help of manual or stationary electromechanical scissors, a workpiece of the required size is cut out of sheet steel;
the prepared workpiece is inserted into the machine with its side;
with the help of a special handle, guides are actuated, bending the entire length of the metal sheet to the required angle;
having thus formed one side of the profile trapezoid, the workpiece moves on the desktop to form the next trapezoid, and so on;
after that, the sheet of metal unfolds and the other side of all the trapeziums of the corrugated board is formed in the same sequence;

You can buy a machine for the manufacture of corrugated board in a variety of modifications. They differ in the amount of equipment. So, for example, some types of machines are equipped with interchangeable dies for the manufacture of various grades of corrugated board. The kit of a manual machine may also include a special roller knife for cutting a metal sheet. Depending on the configuration and manufacturer, the price of a profiled sheet machine may differ several times, so be careful and choose only those options that you really need.

Industrial machines for the production of corrugated board

It is often said that in the factory, the profiled sheet is manufactured on rolling mills. But it is more correct to call them corrugated board production lines, since the rolling mill or the profiled sheet machine is only part of them.

Such a line usually includes the following equipment:

cantilever or two-bearing decoiler;
circular knife for cutting off a steel billet from a roll;
multi-stand rolling mill;
guillotine shears for cutting profiled sheet;
receiving device with a retractable trolley;
automated line control system.

You can buy a machine for the manufacture of profiled sheets in a different configuration. Many manufacturers offer interchangeable rolling mill modules as additional options. Interchangeable modules allow you to quickly switch from the production of one brand of profiled sheet to another, without wasting time on changing the rollers of the rolling mill.

You can also be offered a loader for mounting coils of steel sheet on the decoiler and transporting the profiled sheet from the receiving device to the packaging area or finished product warehouse.

Installing an automation system on the production line allows you to create a high-performance machine for the manufacture of corrugated board, the price of which will be slightly higher than semi-automatic options, but productivity will increase significantly. Namely, the payback period and profitability of investments depend on productivity.

The productivity of the line for the production of corrugated board is determined by the speed of rolling. For modern automated lines, this characteristic can reach 40 m/min. In fact, the productivity of the line is somewhat less than the rolling speed. This is due to the fact that some time is needed to cut each sheet of finished products. Therefore, at a rolling speed of 40 m/min, the line capacity will be 32-34 m/min.

Automation panel on a machine for the production of profiled sheets

The table below shows the cost of production lines for the production of certain types of profiles.

The cost of various machines for the production of corrugated board

Machine for the production of corrugated board, price in rubles. VAT included

Note: The table shows prices for equipment in the basic configuration. You can equip the machine for corrugated board with additional options, while its price will increase by 5-10%.

In order to buy a machine for the production of profiled sheets, it is necessary to make an advance payment in the amount of 10 to 50% of the cost of the rolling line equipment. When paying an advance of 50%, suppliers usually provide a discount of 3-5% of the cost of the corrugated board production line. You can buy a machine for the production of corrugated board with a delay in the second part of the payment or leasing on fairly favorable terms.

The purchased equipment is sent to the customer by road or rail container. The cost of transportation is paid by the recipient. Self-delivery of machines from the manufacturer is possible. In this case, vehicles with a trailer length of at least 12m are required.

After assembly and installation of equipment by the customer, the manufacturer's specialists carry out commissioning work to put the line into operation. The cost of these works is included in the price of the supplied equipment.

The site oprofnastile.ru is up-to-date and useful information about corrugated board, its installation and use, advice from professionals and step by step instructions For you.

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Profiled metal sheets or corrugated board are quite often used in construction. The material is both reliable and inexpensive. As a rule, corrugated board is used during the installation of a temporary structure (for example, a warehouse hangar). The material is also used in the process of installing the roof and in facing works. The production of corrugated board does not involve large expenses. Some construction companies carry out the manufacture of material directly on the sites.

Types of equipment for the production of corrugated board:

mechanical bending machines;
pneumatic;
hydraulic;
magnetic;
semi-automatic;
automatic production lines.

Mechanical sheet benders

For the manufacture of the profiled surface of the metal sheet, the cold stamping method is used. But first you need to pick up a few sheets with a previously applied zinc or polymer coating.

There is a special machine on which corrugated board is made in piece quantity. On it, in particular, you can bend additional elements - skates, valleys, aprons and small sheets of corrugated board.

To bring such a machine into action, the muscular strength of a person is required.

Consider the technical capabilities of metals for processing:

The thickness of the steel should not exceed 1 mm;
The maximum length of the sheet should be about 2 meters;
The bend angle should be 150 degrees.

Place the sheet on the equipped table, press it with a bar and use the lever to bend the desired profile. A manual machine for the production of corrugated board is relatively inexpensive and does not take up much space. This machine is not suitable for bending profiles on plastic sheets as the protective layer may be damaged. Vulnerabilities will rust and the sheet will leak.

Mechanized sheet benders

Mechanized equipment is represented by pneumatic, magnetic and hydraulic machines. The field of application of mechanized equipment does not differ from the field of mechanical equipment. However, the reviews are much better. Listogib has an electromagnetic workpiece clamp. This allows you to bend steel, copper and aluminum profiles. For example, a manual sheeting machine does not bend the workpiece along its entire length and does not automatically determine the angle of 360 degrees.

The pneumatic machine includes a punch. With this fixture a metal sheet pressed into the matrix. Compressed air is needed to drive the punch. The power of such a machine is significantly higher than that of a manual one. It allows with a bending angle of 90 degrees, as well as automatically calculate the length and thickness.

With the help of hydraulic equipment for profiled sheets, you can get different kinds profiles (read: ""). Along with this, the production of large volumes of corrugated board is ensured. Hydraulic Press operates on the same principle as pneumatic. Sheet bender for corrugated board may include numerical control. Presses vary in their performance. If you are using semi-automatic or automatic devices, you can select punch and die settings. This allows you to see the sheet model in the chart and set the speed of work. As a rule, only large factories can afford such expensive equipment. A private firm or individual entrepreneurs can rarely afford to buy a press. Therefore, they use a manual machine for the manufacture of corrugated board.

Technology for the manufacture of corrugated board

In order to produce a large batch of profiled sheets with different characteristics, the cold rolling method is used.

The production line includes:

unwinder;
rolling machine;
scissors;
receiving device;
system automatic control process.

With the help of universal technologies for the production of profiled decking industrial way, it is possible to produce all profiles on one sheet.

The advantages of this method are:

Lack of rolls and errors in geometry.
Precise geometry of each profile.
Uniform tension of the metal along the length and width, as well as high quality work (profile lines do not crack).

Manual machine for the production of corrugated board, see the video:

It is quite profitable to produce and sell corrugated board. That is why the machines are so popular with various enterprises.

The equipment is installed in separate workshops, in which certain requirements must be met:

Using a lifting device that places the rolls on the unwinder. This process cannot be done manually.
Minimum temperature in the workshop should be +4 degrees. This is due to the fact that polymer coatings crack at lower temperatures.
Availability of space for rolls, manufactured orders and other material.

If you decide to use profiled sheets for roofing, then do not forget about sound insulation. Because during the rain, the metal is quite noisy. Profiled sheets can be purchased directly from manufacturers. In addition, you can contact specialized stores that, in addition to selling the material, will provide it with free delivery. If you purchase corrugated board at the factory, then most likely you will transport the material yourself. In any case, before buying profiled sheets, it is important to view the photo and video materials of the Internet. From them you will learn, for example, how a manual sheet bender works for corrugated board.

However, it is worth noting that starting to work in this business area, you need to take into account the level of competition in each particular region. This is due to the fact that the production of corrugated board is available not only to large factories, if any, but also small firms, possessing necessary funds and even individual entrepreneurs.

As for the material itself, corrugated board is actively used in construction or repair work, whether it is the construction of a roof, or wall cladding of garages, utility rooms, warehouses, most often non-residential premises. The material is not bad for the rapid erection of fences and all kinds of fences, sheds and other structures.

This line consists of three main components and includes:

Center for unwinding
Table including roller knife
rolling mill

Organization of mini production of corrugated board.

Decking, depending on the purpose of its use, is of different types.
The main ones are: roofing and wall, load-bearing corrugated board or in the form of a sandwich panel. The average width of corrugated board rolls varies between 980-1850 mm, the length may vary depending on the purpose of use.

If there are large factories in your area that produce this building material, be prepared for the fact that you will have to spend a certain and often considerable amount of money to attract your own buyers in a highly competitive environment.

In addition, in the presence of serious competition, at first you should not hope for a full-fledged profit, since often start-up entrepreneurs have to underestimate the price of their own products in order to win a certain niche in the building materials market.

Things will be much easier if there is not a single plant producing corrugated board at a great distance from your production.
Another positive moment- developed metallurgical production, which will allow to acquire the right materials on affordable price not including long distance surcharge.

When compiling a business plan, also consider the quality and types of products manufactured by competing firms, promotions and special offers organized by them.

In addition, you should pay attention to the features of the region in which you are going to sell corrugated board. How much it will be in demand can be predicted, taking into account, for example, the number of private houses in cities and beyond, buildings under construction, etc.

Business practice.

Statistics show that one of the most popular sizes of corrugated board are 1.5 m, 1.8 or 2 meters. Popular colors remain galvanized, burgundy red, chocolate, and moss green. As for the thickness, most often it is about 0.5 mm.

As some private entrepreneurs note, in order for the business of manufacturing and selling corrugated board to bring tangible income, it is necessary to sell at least 100 square meters that in the presence of regular customers is not so much.

At the same time, it should be borne in mind that the sale of building material is largely a seasonal activity. Most often, orders for the purchase of corrugated board are received from April to November, since in cold weather construction and repair work are suspended.

It will be a good help if you can find a corrugated board production line at an affordable price and fairly cheap materials. This will save money and spend it, for example, on wages workers or electricity bills.

Experience in sales of corrugated board products.

A few more tips. AT winter time, as already mentioned, building material is sold, to put it mildly, it does not matter. To correct this matter a little, you can offer customers more profitable terms. For example, good discounts on goods and various promotions and offers to purchase corrugated board in installments or, for example, take it on credit.

At the same time, it is desirable to limit the duration of discounts to a time frame, in particular, before the arrival of warming and the start of the main sales season. As some entrepreneurs note, the method is quite effective, and you can get a good profit even during a period of reduced sales.

Also, regardless of the season, do not forget about advertising your products. High-quality and well-constructed advertising will significantly increase the number of your regular customers.

After the business starts to bring good profit, you can think about investing in additional equipment, which, in turn, will help to establish production and increase the number of products.
Business Development Perspective.

A promising direction for the development of the business for the production of corrugated board will be the production pencil case garages, warehouses and of course fences. Additionally, for this area, you will have to purchase welding equipment and hire installers.

Production of corrugated board on manual equipment.

Back

Forward -

It is not so difficult to make a bending machine with your own hands, but craftsmen, both home-made amateurs and self-employed entrepreneurs, use it little so far. Meanwhile, the price of only ready-made additional elements of the roof - valleys, ridges, cornice strips - and downpipes with gutters is several times higher than the cost of the material. The same applies to paintings (roofing sheets, quite ready for laying) with flanging edges for a double fold. And that's just roofing.

Meanwhile, many craftsmen still prefer to either buy ready-made parts, losing in earnings, or to do the old fashioned way with a punch, losing potential customers - modern products should not have a horse-drawn look. What is wrong here: economics, technology, prejudices? Or maybe just ignorance? Maybe you just need a clear drawing of a bender, which you could build yourself in a shed, and use it for a long time and successfully? Let's try to figure it out.

Of the main indicators (economy, productivity, simplicity of design), it is also necessary to determine the durability, subject to a stable result of work. At the height of the season, when the day feeds the year, there is no time to mess around with repairs or adjustments, and with occasional use once a month, not every month you can do without special equipment at all, see below.

The minimum requirement is for a jack-of-all-trades who does roofing and tinsmith work from time to time if there are orders; to buy such a machine industrial production hard, won't pay off. But then a home-made sheet bender must withstand at least 1200-1500 working cycles per season without compromising the quality of bending. There is another important point - corrugated board. More precisely, its independent production. It deserves special mention.

Qui prodest?

Translated from Latin - who benefits? Producing corrugated board on your own, at least for yourself, is a very popular material. Let's try to guess.

A manual pass-through type bender (see below) costs about $2000. It seems to be possible to turn a ton of galvanized 0.55 worth $ 1000 into 250 square meters on it in a day or two. m of corrugated board, which would cost $1,400 if purchased. It would seem a direct benefit; especially if you do not wait for a sale (the market is full of offers), but put it into business yourself. Yes, not so.

The corrugated board is not rolled in one pass - the corners in some places turn out to be constricted. Intercrystalline bonds in the metal are broken; the rough section of the bend is not always determined by sight and to the touch, but soon a crack will creep from it. And who will now give an order without a guarantee? Feel free to correct. For yours, of course.

You can reduce the pressure, but then the wave will go non-standard. The customer may not know the standards, but he will immediately see that the material is not the same. Put, be kind, like everyone else, or - goodbye, I'll turn to another. And I will tell my friends. Drive each sheet in several passes, changing the clamp or rollers? What kind of productivity with profitability.

The line (actually, the rolling mill) for corrugated board is a complex unit, see fig. Pay attention to the number and configuration of the rolls. The purpose of such a system is to disperse the residual stresses across the sheet so that they do not go beyond acceptable limits. Therefore, the wave is formed gradually.

Such equipment costs at least $20,000, made in China. Stable quality of finished products is guaranteed only for specific steel grades of a specific manufacturer. Power consumption - from 12 kW. Those. a specialized production area is needed with an appropriate power consumption limit and, although one operator is enough to serve. Is there an unsatisfied demand for corrugated board in your operating area (simply - in the vicinity accessible to you), allowing you to pay for it all in an acceptable time frame? And are you ready to start a very serious business with fierce competition?

Note to masters

Of course, it is not easy to “recapture” $2000 for an individual master. Therefore, let's try to figure out how to make a sheet bender yourself. Not for corrugated board, but for a variety of roofing and tinsmith work, on which you can also live well, and collect some money to start something more serious. A non-standard trifle is fundamentally not amenable to unification, but is always needed. And a homemade sheet bender can be a very good help here.

About purchased handbrakes

To put an end to the "firm" (the article is not advertising) and move on to homemade products, let's look briefly at what you can buy if you still need it. The market is clearly dominated by TAPCO and VanMark. And the domestic SKS-2, produced in Orsk, is almost unknown. For the price, all are about the same; the width of the working area for ours is 2.5 m versus 3 for foreigners, but this is not a vice. 3 m is calculated on an inch system of measures (10 feet \u003d 3.05 m), and in metric 2.5 m is just more convenient.

But the Uralian is a passing type; it is possible, for example, to pull gutters up to 90x90 mm. Raising / lowering the traverse - eccentrics, no need to turn the flywheels. Complete with cutting blade. User reviews are not only favorable, enthusiastic. The general tone is "an indispensable hard worker."

History repeats itself. Nikita Khrushchev spoke about such situations live on the Central Television after his trip to America (this is when he beat his shoes on the UN platform and threatened to make everyone go to hell) Nikita Khrushchev. Like, in the States they know how to sell any obscene rubbish, but in our country they cannot properly submit the necessary good things.

Sheet bending structures

Drive unit

Bending and pressing equipment with a mechanical drive (a flywheel with a friction clutch and a crank or a falling weight with a system of pulleys, cables and levers) has a high efficiency, but is still a thing of the past. The mechanics gives a sharp impulse (blow) at the beginning of the working stroke, and towards the end it weakens. For bending/pressing, just the opposite is needed.

The efficiency of the electric drive decreases rapidly with a decrease in the size of the workpiece. To mold the corrugated board on the mill described above, 12 kW is enough. To make a flanging on the roof picture, you can’t do less than 1.5-2 kW. The fact is that the external characteristic of AC electric motors (except for three-phase ones with a phase rotor - complex, expensive, requiring regular maintenance) is quite tough. From the resistance of the bending metal, the engine does not increase the torque on the shaft, but on the contrary, the rotor slip increases and the torque drops. And the energy consumption is increasing.

The hydraulic drive, in theory, is ideal - the hydraulic cylinder itself automatically adjusts its force to the resistance of the part. But precision hydraulic systems are complex and expensive. Even an experienced designer will not undertake to distribute the force of, say, a car jack evenly along the entire length of a meter-long bend, as well as synchronize the work of two or more with improvised means.

It remains "handbrake", and it's not so bad. If you design a bender so that, as in swing rowing or powerlifting, the strongest and most enduring muscles work (biceps, latissimus dorsi, hips, calves), and the reaction (recoil) of the machine presses the feet to the floor, then the work, due to its cyclicity, will not will be exhausting. But a skill will be developed that will give accuracy and productivity.

For example: an average person running up a flight of stairs can develop a power of about 1 hp within 1-2 seconds. But already on the third flight, the muscles will switch from oxygen to glycogen, lactic acid will begin to be released, and fatigue will hit the body. You need to take a break to move on.

For sports information: the rowers are lean, because the "kendyukh" makes it difficult to give a full go-ahead with the body. But for weightlifters, the “corn”, on the contrary, helps to keep balance when jerking. But the work of the musculature of both is in many respects similar.

Schemes and purpose

Listogib - the concept is quite general. The device of the sheet bender depends on its purpose. According to the nature of the work, you need to choose a homemade scheme, see fig.

At pos. A - a method familiar to anyone who has even a little locksmithing. So you can simply bend sheets up to 0.5 m wide with your hands. If the bend length is not more than 200-250 mm, then the base can not be attached to the workbench, but together with the clamping beam and the part, clamp it in a vice. The fold turns out to be good if you lean more on the traverse at the bottom, as shown in the diagram of forces, and move a little forward, as if smoothing out the fold. Most of the designs of home-made bending machines are based on this principle; we'll still get there.

Due to the elasticity of the metal, bending the sheet exactly at 90 degrees will not work, so spacers are used from a strip of metal, as shown in the inset. Why are there channels on the section, and not corners? Let's take a look at this question next. elementary simple-looking design has significant nuances.

Pos. B shows how a press brake works. A press is like a press: bed-matrix-punch-hydraulics-blow-ready. These are used only in industrial production with a developed system of labor protection: they are complex, expensive, require qualified care and are extremely traumatic. A sheet that has slipped out from improper refueling or equipment malfunction can cut off a person’s hand or head.

At pos. B - broaching (through) sheet bending. By changing the mutual arrangement of the rolls, it is possible to set the bending radius of the sheet. The pass-through sheet bender can be either manual or electrically driven. Commercially available, as a rule, are multifunctional:

Smooth rolls are designed for tinsmith work - bending shell shell blanks, sections of wide pipes, etc.
The rolls can be replaced by complete profiled sheet-bending rolls designed for pulling roof extensions - ridges, valleys, gutters and flanging.
Also, many models are equipped with a support, clamp and traverse for manual bending of sheets.

It is these benders that sell for $2,000 or so. Many are equipped, or later you can buy them, with shaped rollers for corrugated board, but, as already discussed, you cannot “drive a shaft” for sale on them. You can roll a piece if you need it right now, but it makes no sense to buy a whole sheet.

Note: there is another interesting type of bending device, but due to its high utility and relatively low cost, a separate section will be devoted to it.

We take up sheet bending

We will begin the manufacture of our bending machine with the development of the simplest specifications. And we will calculate the latter, in addition to the durability criteria described above, based on the consumption of muscular energy, which an average adult man is able to produce day after day without worsening his well-being. Of course, the simplicity and cheapness of the design is also not in last place. Also, the machine, in terms of weight and dimensions, must allow transportation in a passenger car and use directly at the place of work. It turns out:

The width of the bent sheet is up to 1 m.
Thickness of the bent sheet - up to 0.6 mm galvanized; up to 0.7 mm aluminum and up to 1 mm copper.
The number of operating cycles without readjustment and / or repair is at least 1200.
Flexion angle - not less than 120 degrees without manual finishing; so it is necessary for folds.
The use of special steels or non-standard blanks is highly undesirable.
Welding - as little as possible; parts / assemblies lead from it, and welds are fragile and quickly get tired of alternating loads.
Metalworking on the side (turning, milling) - also as little as possible, it costs money.

Let's face it: drawings of finished structures that meet all these requirements are not found in public sources. We will try to improve one, widely known, and, in principle, very successful.

We bring to mind

Incision

The principle of the device of this sheet bender is clearly visible in the section (see the figure on the right and the list of positions). Its main advantage is good ergonomics. With such a working stroke, the muscles work as they should, and the feet are pressed to the floor, which even for an inexperienced operator will give a stable result. And the maximum bending angle is 135 degrees, which is with a large margin for any conceivable and unthinkable elasticity of the bent sheet.

wooden pillow;
support beam - channel 100-120 mm;
cheek - from a sheet of 6-8 mm;
workpiece;
clamping beam (clamp) - welded from corners 80 and 60 mm;
traverse axis - pin 10 mm;
rotary traverse - corner (?) 80-100 mm;
handle - bar 10 mm.

The material of all parts is ordinary structural steel. But already here it is conditionally shown that it is better to replace the traverse from the corner with a channel of the same size. Why? Let's take a closer look, this is important for the future.

The reaction (recoil) from the bent sheet to the traverse (and clamp, but more on that later) is uneven in width. In the middle, where each elementary (tiny; this is a hint at differentiation and integration) metal section is surrounded on all sides by the same metal, it is maximum. At the edges, where there is no side support, it is minimal.

The second point is the sheet, although thin, but of finite thickness. Stresses in the workpiece will spread, reflected on the edges. As a result of the diagrams of the load on the traverse and the clamp, it will take the form of a bow with a bowstring. On the free (far) edges of the corner shelves, such a load will give a tensile force, and the metal does not work well in tension - it quickly gets tired of it. The do-it-yourselfer who built such a machine soon discovers that the corner in the middle is bent and the fold in the middle is swollen.

The side shelves of the channel are wedge-shaped, and there are more developed ones in it than in inner corner corners, fillets. This, firstly, smooths out the diagram - the bowstring is barely stretched. Secondly, the superfluous, it would seem, side flange of the channel draws tensile stresses onto itself, which are converted into compression at its free edge. And the compression holds the metal - wow!

The result of the calculation is impressive: if the traverse from the corner can withstand a couple of hundred bends at most, then the channel of the same width is more than 1200! What is 200 bends? One or a little more roof at best. At the height of the season, when customers stand in line, the machine deteriorates, and the work has stopped. And 1200 operations means that the season will survive. In winter, there will be time to trim, or replace the traverse, or, having calculated the proceeds, buy a “company” with a guarantee of a resource.

Detailing

In the next figure, there is already a detail with a list of positions. Here, not only do you need to eliminate some shortcomings, but you can also improve something further.

clamp - corner 40-60 mm; screw M8-M10 with a knob and a heel;
cheek;
support beam;
bracket - corner 110 mm;
clamping beam;
traverse axis;
traverse.

pressure beam

First of all - about milling the lower surface of the clamp on the plane. It is needed for any of its designs, and the permissible unevenness is no more than half the thickness of the bent sheet (minimum! Let's assume it is equal to 0.2 mm). Otherwise, the sheet will crawl (leak) under pressure - and again a pot-bellied fold.

So for anyone who himself at least once did something for metal, the advice to smooth the clamp with a file or a grinder will only cause a smirk. It needs to be sent for cutting. Moreover, AFTER welding the entire assembly, when everything that could have happened has already happened. Otherwise, the work and payment of the router will be in vain.

Further, everything that has been said above about the load on the traverse is also true for the clamp. And its most loaded part - the leading edge - is not supported by anything. It is impossible to reinforce or replace the entire assembly from the corner with a channel: the bend angle will be no more than 90 degrees.

As a result, after the same 100-200 operations, the machine will “open its mouth” (or “smile”, if you prefer white rather than black humor) and the same swollen bend. Up the clamp will not bend; in this respect it is well fortified. But the metal on the leading edge will simply leak from fatigue.

A section of the clamp design, which is equal in durability to the traverse, is shown in the inset at the top right. The basis is a steel strip 16x80 mm. The front edge is milled at 45 degrees, and a chamfer is removed on the same milling cutter for at least 2.5-3 MAXIMUM thicknesses of the bent steel sheet, i.e. 1.5-2 mm. From the deflection upward, the clamp is reinforced with a sixty-corner for welding. Milling, again, after all welding work.

The idea is this: if in the previous design the leading edge works half in bending (which is even worse for metal in tension), then in the new one it works only in compression. At the same time, the general support on the edge will not allow it to leak soon.

Note: if nearby, somewhere in a landfill, an ancient ruined lathe- the problem of the traverse with the clamp is solved once and for all. From the bed, you can cut out pieces of the desired configuration, made of special steel and excellent accuracy.

In terms of the number of working operations for manufacturing, both clamps are equivalent: cutting, drilling, welding, milling. The material consumption of the new clamp is higher than the old one; standard sizes of blanks for both require three. But the ratio of durability is the same as for the two types of traverses described above.

Table mount

The next step is clamps. The author of the design, of course, clearly imagines the role of stiffeners, but it seems that he has lost sight of the fragility and fatigue of welds. And the working stroke of the traverse gives a variable tensile force on the clamps with lever arms of 10:1 or more. If the clamp breaks, the work is over, even if everything else remains perfectly even. The machine will lift itself, not bend.

Why not get rid of clamps altogether? And then cheeks will not be needed, and welding for both. How to do it?

Extend the support beam to the sides beyond the table.
Choose U-shaped eyes at its ends.
Fasten to the table with bolts somewhere M10 with shaped nuts - paws.

The second option is the holes in the paws without thread. The bolts are turned over and tightened with wing nuts. A little more expensive, but easier to work with.

Traverse fastening

Here the question arises: how to fix the traverse, since there are no more cheeks? Yes, they are not needed. Firstly, the design turns out to be non-separable, and the traverse will have to be changed once a year. Secondly, remember, we need an accuracy of about 0.1 mm, otherwise the fold will swell. How soon will the pin break a simple “hole” in the cheek by a large amount? The question is rhetorical. And at the same time I apologize to my fellow engineers: of course, I know that a hole is somewhere in someone, but in metalworking there is a hole.

But how then to fix the traverse? Butterfly door hinges; the lower right inset in Fig. They do not require tie-ins (invented specifically for metal doors), and two such hinges hold the door, armored from the line of "Kalash" or F-1 grenades. It takes six healthy men to put one up.

In terms of accuracy, most butterfly loops pass the bang test without difficulty. If you quickly separate the loop, then a smacking sound is heard from the air that replaces the vacuum formed when the pin is pulled out. That is, the fit of the parts is very tight, but rotate easily.

Butterflies are fastened with countersunk screws. If you put it on an iron red lead, the traverse will stand indestructibly. Opening angle - 160 degrees. Probably, the inventor of butterfly loops once made a home-made sheet bender. Such a joke.

Assembly

Finally, in front of you is an assembled sheet bender:

support beam;
threaded (M10) flywheel;
clamping beam;
processed sheet;
clamp (see previous);
traverse.

There is only one remark to be made here. Perhaps the author of the design had flywheel nuts lying somewhere in the stash, which is why he installed them. In fact, to put the next sheet, you will have to raise the clamp by only 2-3 mm. Well, by 30 mm, if you need to take out a picture with a fold already molded on the other side. Thread pitch M10 remember? That is, you do not need to turn the flywheels for a long time, like a gun when aiming. There are enough wing nuts or even ordinary ones with welded collars.

Note: after welding on the knobs, it is imperative to drive the thread “to the full” - by holding the nut in a vice, and with the first, and then with the second tap, or with a machine single-pass. From welding, the thread leads so that oh ...

Video: an example of a finished homemade sheet bender

Zig machine

The Zig-machine is, of course, not a robot in the form of a screaming Hitler with an outstretched hand. Zigovochnaya machine (see. Fig.) or zigmashina - a device for zigovka, or zigovirovanie. And zigovka - stretching on sheet metal flanging or special potholes - zigs. Have you seen the stiffeners on buckets and basins? This is the ridges. Actually machines for brevity are also often called zigovka

Zigovochnye machines, as follows from the definition, also belong to the category of sheet bending equipment, only special. They are either electric or manual. The latter are desktop stationary (in the figure) or portable (mobile), with a clamp. These can be carried with you in your tool bag.

Zigmashina is an indispensable assistant in tin and roofing work. You can zigue not only round billets of shells, but also sheets. Try on the best manual sheet bender to make a bend under the already mentioned double fold. Such a zigovka is obtained in one pass; with some skill - right on the roof. What else can be obtained by zigovka using standard pairs of rollers can be seen in the following figure. Letter designations standard; they correspond to the type of operation being performed. The zigovka costs three to five times, or even ten times cheaper than the factory manual bending machine.

Video: work on a zig machine

What to whom?

Let's summarize - which sheet bender is better for whom:

For an amateur do-it-yourselfer - bending with improvised means, as described, or home-made manual, if there is a supply of junk and a desire to tinker.
To the master-universal worker, who from time to time receives orders for tin or roofing - a home-made manual like the one described plus, if there is some excess of funds - a zigmachine.
Roofer or tinsmith - a professional who has a stable flow of orders - branded manual with a sigmachine.
For mass production of corrugated board, standard roofing elements or sheet metal structures - specialized industrial equipment for the appropriate purpose.

Last note: for stable work results with a dense flow of orders, you still should not rely on a home-made bending machine - the metal in the structure is not the same, it will soon float from fatigue.
(1 ratings, average: 4,00 out of 5)

The production of a reliable, small in weight and inexpensive profiled sheet used in the construction industry of our days is carried out on special manual and automatic equipment.

1

Decking is a universal modern material for the construction of low-rise buildings, wall cladding, roofing and other construction tasks, made from galvanized steel cold-rolled sheet. To give such rolled products the required shape, only two methods are used - hot and cold rolled. Both of these operations involve the passage of flat sheets of steel through special shafts.

Hot-rolled technology, due to its features, is available exclusively at large metallurgical plants.

But the cold rolling of steel billets in order to obtain from them can be performed in semi-professional and even amateur conditions. The main thing here is to choose the right equipment and learn how to use it correctly.

The cold rolled production technology consists of two consecutive procedures. First, the workpiece is passed through the rollers, and then the resulting corrugated board is cut according to the given geometric sections. The shape of the rollers determines, as you yourself understand, the shape of the finished product.

2

Production is possible on installations of three main types:

manual machine;
mobile (mobile) equipment with partial automation of work operations;

Any person can use an elementary machine for the production of profiled sheets, but on condition that he is ready to make quite serious physical efforts to process steel sheets. On manual installations, workpieces of small thickness are usually rolled. The quality of the resulting products is at a low level. In most cases, such a machine is used for the production of profiled sheets for fences and fences.

Manual equipment does not have to be purchased ready-made. On the Internet there are a huge number of detailed drawings and diagrams, guided by which you can independently make the simplest bending machine. We note again - it makes no sense to use it for the production of really high-quality profiled sheets. You simply won't be able to do anything.

Semi-automatic equipment is in no way inferior to fully automated lines in terms of the efficiency of its work and the quality of the profiled products. At the same time, it is mobile, which in some cases is of great importance.

A stationary automatic line is a whole complex of units. Depending on the specific configuration, it may include the following settings:

directly rolling mill with rollers of several sizes;
device for cutting profiled sheets;
equipment for applying a polymer coating to finished products.

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Experts say that the following mechanisms and devices should be present in the minimum configuration of automated equipment for the production of high-quality profiled sheets:

The corrugated board production line is controlled by a special system. It can be both relatively simple and really complex. A simple control system does not provide a high level of automation of the production process, but people with low qualifications can work with it. But a complex equipment control complex increases the efficiency of the line. True, not everyone will be able to deal with such a system, for its use it is necessary to attract specialists with a large amount of technical knowledge.